Beverage cartridge filling and sealing system

ABSTRACT

Disclosed herein is a beverage cartridge assembler. A dispensing element stores a certain amount of a substance for brewing. A carriage secures an open beverage cartridge beneath the dispensing element. Actuation of a lever rotates the dispensing element to release a certain amount of the substance from the dispensing element into the open beverage cartridge. The lid of the beverage cartridge is sealed as the carriage moves along a first axis. A beverage cartridge includes sidewalls with a plurality of vertical notches to permit the sidewalls to flex inward. The sidewalls include a first filter, and a bottom portion that includes a second filter thicker than the first filter.

CROSS REFERENCE TO RELATED APPLICATIONS

The instant application claims the benefit of U.S. Provisional Patent Application No. 62/689,750 filed Jun. 25, 2018, and U.S. Provisional Patent Application No. 62/769,087 filed Nov. 19, 2018, the contents of which are incorporated herein by reference in their entirety.

BACKGROUND

In recent years, single cup brewing systems have gained popularity due to their ability to produce hot beverages seamlessly and swiftly. Such brewing systems typically work in conjunction with a single-serve pod or cartridge filled with coffee grounds, tea leaves, cocoa powder, fruit powder or the like. A conventional brewing apparatus may, for example, pierce the top and bottom of a single-serve cartridge, force hot water therethrough, and discharge the resulting beverage into a cup. In a matter of seconds, the brewing process is complete and a user may consume the hot beverage.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is the external housing of an illustrative beverage cartridge assembler in accordance with the present disclosure.

FIG. 2 is an illustrative beverage cartridge assembler with the housing removed.

FIG. 3 shows illustrative interior components of a beverage cartridge assembler in accordance with aspects of the present disclosure.

FIG. 4 is a cross section view of an illustrative beverage cartridge assembler apparatus in a filling state, in accordance with aspects of the present disclosure.

FIG. 5 is a cross section view of an illustrative beverage cartridge assembler apparatus in a sealing state, in accordance with aspects of the present disclosure.

FIG. 6 is a working example of a filling and sealing mechanism in accordance with aspects of the present disclosure.

FIG. 7 is a further example of a beverage pod filling mechanism in accordance with aspects of the disclosure.

FIG. 8 is a cross section view of an example sealing lever in accordance with aspects of the disclosure.

FIG. 9 is an example beverage cartridge in accordance with aspects of the present disclosure.

FIG. 10 is a cross section view of an example beverage cartridge in accordance with aspects of the present disclosure.

FIG. 11 is a cross section view of an example beverage cartridge with an inserted brewing needle in accordance with aspects of the present disclosure.

FIG. 12 is a perspective view of an illustrative beverage cartridge in accordance with aspects of the present disclosure.

FIG. 13 is a further example beverage cartridge in accordance with aspects of the present disclosure.

FIG. 14 is a cross section view of a further example beverage cartridge in accordance with aspects of the present disclosure.

FIG. 15 is yet another example beverage cartridge in accordance with aspects of the present disclosure.

FIG. 16 is a cross section view of an example beverage cartridge in a brewing chamber.

FIG. 17A is a further cross section view of an example beverage cartridge in accordance with aspects of the present disclosure.

FIG. 17B is yet a further perspective view of an example beverage cartridge in accordance with aspects of the present disclosure.

FIG. 18 is an example beverage cartridge assembler with a coffee bean grinder.

DETAILED DESCRIPTION

As noted above, single cup brewing systems may work in conjunction with a single-serve pod filled with coffee grounds, tea leaves, cocoa powder, fruit powder etc. These pods are mass produced with a predetermined type and quality of beverage in the pods. Manufacturing chains predetermine the freshness and brew strength of the coffee grounds, tea leaves, or the like based on the cost-benefit of production. Unfortunately, beverage consumers who desire the convenience of single cup brewing systems, but are particular about the quality of their beverage, are left without options. That is, consumers desire fresh, custom strength beverages of any brand, without sacrificing the convenience of prepackaged beverage cartridges.

In view of the foregoing, disclosed herein are beverage cartridge assembler apparatus and example beverage cartridges. In on example, a beverage cartridge assembler apparatus may include a dispensing element to store a certain amount of a substance for brewing and a carriage comprising a pair of cupping arms to secure an open beverage cartridge beneath the dispensing element. In a further example, the carriage may include a rotating lid holder on which to situate a lid of the open beverage cartridge. In another example, a lever may be linked to the dispensing element so as to rotate the dispensing element, in response to the lever being actuated, and release a certain amount of the substance stored in the dispensing element into the open beverage cartridge. In a further example, the beverage cartridge assembler may include a lid closing pin arranged to contact the rotating lid holder of the carriage to rotate the lid holder and seal the lid of the beverage cartridge as the carriage moves in a first direction along a first axis.

Several examples of beverage cartridges are also provided herein. In one example, a beverage cartridge may include sidewalls in a first position The sidewalls may have a plurality of vertical notches so as to permit the sidewalls to flex inward into a second position, in response to pressure being applied on the beverage cartridge. The sidewalls may be capable of returning to the first position, in response to the pressure on the beverage cartridge being released. In a further example, a beverage cartridge may include a sidewall that includes a first filter, and a bottom portion that includes a second filter thicker than the first filter. The beverage cartridge may also contain a plurality of slits on the bottom portion to support the second filter.

The aspects, features and advantages of the present disclosure will be appreciated when considered with reference to the following description of examples and accompanying figures. The following description does not limit the application; rather, the scope of the disclosure is defined by the appended claims and equivalents.

Referring to FIG. 1, a general view of an illustrative beverage cartridge assembler 100 is shown. As will be discussed in more detail, the beverage cartridge apparatus may be designed to fill and seal a beverage cartridge. The beverage cartridge assembler 100 may contain housing 101 that may include a hopper 119 for storing a substance for brewing (e.g., coffee, tea etc.). The hopper 119 may further include a removable hopper lid 121. FIG. 1 also depicts a spring-loaded dispensing lever 107 that dispenses a brewing substance into a beverage cartridge, in response to a user actuating the lever. FIG. 1 further depicts a handle 106 that may be pulled by a user. In response to a user pulling handle 106, a pre-filled beverage cartridge may be sealed and unveiled. Once unveiled, a user may remove the beverage cartridge for later use in a beverage brewing apparatus. The beverage cartridge assembler may further comprise a chamber door 142 that may be removed to insert additional empty beverage cartridges for filling.

FIG. 2 portrays some of the inner features of the example beverage cartridge assembler 100. FIG. 2 depicts a storage chamber 102 that may store up to thirty nested beverage cartridges 200. However, it is understood that alternate designs may permit more or less than thirty beverage cartridges. A beverage cartridge guide 141 may be positioned such that a beverage cartridge 200 cannot be inserted into the beverage cartridge storage chamber 102 improperly. As discussed earlier, a substance for brewing may be stored in hopper 119. The substance may later be released into a beverage cartridge 200. As noted above, handle 106 may be pulled by a user to seal and unveil a ready-to-brew beverage pod. Handle 106 may horizontally move carriage 104. As will be discussed in more detail below, carriage 104 may hold a given beverage cartridge 200 during the filling and sealing process. The sliding linkage arm 112 may be arranged and configured to initiate the release of a new, empty beverage cartridge 200 into the moveable carriage 104.

FIG. 3 illustrates additional inner features of the example beverage cartridge assembler 100. FIG. 3 depicts a dispensing element 125 used to dispense a predetermined amount of a substance for brewing into a beverage cartridge 200 placed within the carriage 104. The substance may be dispensed via a funnel 127. Rotating sleeve 113 may be rotated by the sliding linking arm 112 shown above in FIG. 2 to release the lowest beverage cartridge 200 from the stack of beverage cartridges. As will be shown in more detail below, as a user pulls carriage 104, carriage pin 117 may contact sliding linkage arm 112 shown in FIG. 2. In turn, sliding linking arm 112 may rotate rotating sleeve 113 via a wedge 139 to release another empty beverage cartridge 200 into the carriage. The rotating lid holder 131 may be positioned at an angle such that it rotates towards the open top of beverage cartridge 200, thereby closing the lid of beverage cartridge 200, as a user pulls carriage 104 using the handle 106. Carriage 104 includes a carriage bearing surface 105 to reduce friction during the horizontal movement. An overflow tray 128 may be positioned underneath the funnel 127 to store excess ground coffee or tea that accidentally falls out of the beverage cartridge 200. The overflow tray 128 may be removable to allow for easy cleaning. The wedge 139 may allow only a single beverage cartridge 200 to fall down onto the tray ribs 129.

FIG. 4 is a cross-sectional view of the illustrative beverage pod assembler. The hopper 119 showed earlier in FIG. 1 may further include a removable hopper lid 121 with a hopper lid seal 122. The hopper lid seal 122 may create an airtight seal at the hopper upper opening 123. A flexible seal 120 may also provide a pathway for the ground coffee to fall through the hopper lower opening 124 into the dispensing element 125. The flexible seal 120 may also provide an air tight seal between hopper lower opening 124 and the dispensing element 125 such that the ground coffee does not become stale due to oxidation. The beverage cartridge 200 may contact a beverage cartridge backstop 126 in order to properly position the beverage cartridge 200 at filling station 143. FIG. 4 shows the spring-loaded dispensing lever 107 depressed downward to rotate the dispensing element 125, which in turn dispenses, for example, ground coffee or tea into a beverage cartridge 200 below.

FIG. 5 is a further cross-sectional view of the beverage pod assembler that illustrates a sealing process as a user pulls the carriage 104 using handle 106 along a horizontal axis into a sealing station 144 and then removal station 145. FIG. 5 shows the spring-loaded dispensing lever 107 released to the original position and the carriage 104 moved horizontally towards the lid closing pin 130. The rotating lid holder 131 may be positioned at an angle such that when contacting the lid closing pin 130, the rotating lid holder 131 rotates towards the open top 201 of the beverage cartridge 200, which in turn closes the lid 210. The correct angle is determined by having a spring-loaded pin 133 contact the rotating lid holder 131. The lid 210 securely fits into the open top 201 using an interference fit. As discussed above, the carriage 104 includes a carriage bearing surface 105 to reduce friction during the horizontal movement.

FIG. 6 is a cut-away view of the beverage assembler apparatus that depicts another perspective of the carriage 104 pulled outward to unveil a beverage cartridge 200. At this stage, the sealing process may be complete and the beverage cartridge 200 may now be considered to be located at the removal station 145. As noted above, the rotating lid holder 131 may automatically rotate open due to a lid holder torsion spring 132. The user may then remove the filled and sealed beverage cartridge 200 from the carriage 104. As the carriage moves past the lid closing pin 130, an empty beverage cartridge may be released into carriage 104 using a series of mechanical linkages. Specifically, the carriage pin 117 may contact the sliding linkage arm pin 116, which may move the sliding linkage arm 112. As noted earlier in FIG. 2, sliding linkage arm 112 may rotate rotating sleeve 113 via wedge 139 to release the lowest empty beverage cartridge 200 from the beverage cartridge storage chamber 102. The wedge 139 may release a single beverage cartridge 200 into the tray ribs. FIG. 6 also illustrates an example method of sealing the beverage cartridge 200 by including a ring-shaped heating element 146 to the rotating lid holder 131. When the beverage cartridge 200 enters the sealing station, the ring-shaped heating element 146 may be activated to permanently seal the lid of beverage cartridge 200. Stationary cupping arms 134 may securely hold the beverage cartridge 200.

FIG. 7 is a further cut away view of the beverage pod assembler depicting the carriage 104 returning to the closed position, which may also align the beverage cartridge 200 that was previously released from the beverage cartridge storage chamber 102 directly below the funnel 127. The beverage cartridge 200 is securely positioned in the carriage 104 by flexing the beverage cartridge sides 203 between two stationary cupping arms 134. As will be discussed further below, the rim of the beverage cartridge 200 may include pressure relief grooves to allow easier flexing of the sides 203 and therefore easier pushing of the carriage 104 by the user. When the carriage 104 is moving towards the closed position, carriage pin 118 may contact the sliding linkage arm pin 116 shown in FIG. 6 to move the sliding linkage arm 112, also shown in FIG. 6. The in-motion sliding linkage arm 112 may rotate rotating sleeve 113 such that another empty beverage cartridge 200 falls into position below the wedge 139 and onto the top surface of the rotating sleeve 113.

FIG. 8 generally depicts an illustrative mechanical linkage between the spring-loaded dispensing lever 107 and the dispensing element. Upon actuation of lever 107, dispensing linkage arm 108 may be turned clockwise, which may turn connecting gear 110 and dispensing element gear 111. Dispensing element gear 111 further turns dispensing element 125 as illustrated in the previous figures.

FIG. 9 is a close up illustration of an example beverage cartridge 200. Beverage cartridge 200 may include sides 203 which may be generally cylindrical, a top 201, a rim 202, a lid 210 that may be permanently attached to the rim 202 by means of a hinge 209. The rim 202 may include pressure relief grooves 204 to permit inward flexing of the sides 203 with less force. That is, the pressure relief grooves 204 may reduce the force exerted by the stationary cupping arms 134 illustrated earlier in FIG. 6. The beverage cartridge 200 may also include an inner sidewall 212 and an outer sidewall 211, which will be discussed in further detail below with reference to FIG. 11.

FIG. 10 is a cross sectional view of a beverage cartridge 200. FIG. 10 shows an illustrative hinged center flap 214 at the center of the lid 210 which may prevent, for example, ground coffee or tea from inadvertently exiting the sealed beverage cartridge 200. The hinged center flap 214 may be constructed such that it is integrated into the lid 210 to reduce the number of steps required to manufacture beverage cartridge 200.

FIG. 11 is a further cross sectional view of a beverage cartridge 200 that shows an upper needle 216, from a given brewing apparatus, bending the hinged center flap 214 during an illustrative brewing process. The hinged center flap 214 may be constructed such that the upper needle 216 bends but does not break the hinged center flap 214 due to the thicker material and hinged design of the hinged center flap 214. A filter 206 may be made out of non-woven polypropylene film. This sturdy material may allow the filter bottom 208 to contact a lower needle 217 without being pierced during the brewing process. The open bottom 205 may reduce the amount of material used and may also provide more surface area for the beverage to exit the filter sides and filter bottom 208. The outer sidewall may create an interference fit with the sides 203, shown earlier in FIG. 9 to prevent water leakage during the brewing process. The inner sidewall 212 (shown in FIG. 9) may be at an angle such that when the lid 210 is closed and downward force is applied to the center cavity 215, the inner sidewall 212 transfers the force to the outer sidewall 211 (shown in FIG. 9), creating a tighter fit which further prevents water leakage.

FIG. 12 illustrates a top perspective view of the beverage cartridge 200. In this example, the hinge 209 may be offset to one side of the rim 202 as well as one side of the lid 210. This configuration may be useful to prevent the user from improperly inserting the beverage cartridge 200 in a beverage cartridge assembler 100.

FIG. 13 is another example beverage cartridge 200 with stiffening ribs 213 arranged on the inner sidewall 212. In this example, stiffening ribs 213 may improve the transfer of force to the outer sidewall 211.

FIG. 14 in another example beverage cartridge 200 with a lid 1402. In this example, lid 1402 is a thin film that may be easily heat sealable. When material generally thicker than 0.01″ is pierced, the beverage cartridge may stick to the needle during removal, causing the brewing machine to jam. Therefore, when thicker material is used for the lid, it may be desirable to use a hinged center flap 214 that bends when contacted by an upper needle 216 (see FIG. 11) instead of being pierced.

FIG. 15 is yet another example of beverage cartridge 200. FIG. 15 shows vertical notches 220 on the sides of beverage cartridge 200. These notches may allow for compact nesting of multiple empty beverage cartridges in the storage chamber 102 shown earlier (e.g., as shown in FIG. 2). The sidewalls flex inward as the beverage cartridges are stacked and return to their original position once de-nested. This maximizes the amount of volume inside the beverage cartridge for ground coffee while allowing approximately 30 empty beverage cartridges to be nested inside the storage chamber. The vertical notches 220 may also reduce the overall height of stacked beverage cartridges by approximately 2 inches.

FIG. 16 shows an illustrative beverage cartridge 200 in a brewing chamber 218. The sides 203 of the beverage cartridge 200 are constructed at a diameter and angle such that when inserted into brewing chamber 218, the sides 203 are at a distance less than approximately 0.005″ to the brewing chamber walls. For example, the diameter may be between approximately 1.837 inches to approximately 1.897 inches and the angle may be approximately 5 degrees from parallel to the brewing chamber walls. This prevents water from leaking around the lid during the brewing process. Since the sides 203 are in contact or very close to contacting the brewing chamber 218, there is very small amount of space for the warm plastic to deform and allow water to escape around the lid. Prior methods require an o-ring, adhesive, or heat sealing to prevent leaking. With the example shown in FIG. 16, very thin plastic may be used for the beverage cartridge that would otherwise warp and leak. Also, the angle of the sidewalls of the pod allow for the diameter of the brewing chamber to vary slightly while still creating a leak-proof seal around the lid.

FIG. 17A shows a further example beverage cartridge 200. In this example, two filters are shown. The first filter 207 is shown constructed on the sides of the beverage cartridge 200. The second filter 208 is shown on the bottom of beverage cartridge 200. A third filter 221 is also shown at the bottom of beverage cartridge 200. The first filter 207 along the sides may be thin (approximately 0.005″) to allow for efficient stacking and for partial filtering of solids. The second filter 208 may also be a thin filter. The third filter 221, which may be disposed on the top or bottom of second filter 208, may be thicker (approximately 0.010″) to prevent undissolved solids from escaping the beverage cartridge 200 during the brewing process. Third filter 221 may provide a second layer of filter for any sludge that made it through second filter 208. FIG. 17B shows lower slits 222 in the bottom of the beverage cartridge 200. This allows the liquid to escape efficiently during the brewing process while also providing support to the filter 206.

In one example, the material used to construct beverage container 200 may include recyclable polypropylene as well as compostable materials such as, but not limited to, polylactic acid (PLA). In another example, the materials used to construct beverage cartridges 200 are increased in thickness and strength such that the beverage cartridge 200 is reusable after cleaning. The material could also be stainless steel. In a further example of the beverage cartridge assembler 100, all parts that come in contact with food substances are manufactured with non-hazardous materials conforming to international food safety standards. This includes the hopper 119, hopper lid 121, hopper lid seal 122, flexible seal 120, dispensing element 125, funnel 127, grinder 135, and beverage cartridge 200.

FIG. 18 illustrates yet another embodiment of beverage cartridge assembler 100 that may be used specifically for whole bean coffee. FIG. 18 depicts hopper 119, which may be used to store whole bean coffee, and a grinder 135 in lieu of dispensing element 125 discussed in earlier examples. In the example of FIG. 18, grinder 135 may be the mechanism that dispenses ground coffee. Grinder 135, which may be activated by a start button 136, may grind whole bean coffee and dispense the ground coffee into beverage cartridge 200 below. The grinder 135 may run for a predetermined amount of time. Grinder 135 may be adjusted by a user configurable dial 137 to vary the amount of ground coffee dispensed into the beverage cartridge 200. In another variation, the user configurable dial 137 may be a set of three grind selection buttons, each set for a specific amount of grinding time, allowing repeatable and quick selection of the amount of coffee to be dispensed.

Advantageously, the above apparatus allows beverage consumers to seamlessly create their own customized beverage cartridge for use in currently available brewing systems. The beverage cartridges disclosed herein also allow for efficient stacking of empty beverage cartridges within the apparatus and for efficient filtering of the beverage. In turn, consumers can enjoy the convenience of single cup brewing systems without sacrificing quality.

Although the disclosure herein has been described with reference to particular examples, it is to be understood that these examples are merely illustrative of the principles of the disclosure. It is therefore to be understood that numerous modifications may be made to the examples and that other arrangements may be devised without departing from the spirit and scope of the disclosure as defined by the appended claims. Furthermore, while particular processes are shown in a specific order in the appended drawings, such processes are not limited to any particular order unless such order is expressly set forth herein. Rather, various steps can be handled in a different order or simultaneously, and steps may be omitted or added. 

1. A beverage cartridge assembler comprising: a dispensing element to store a certain amount of a substance for brewing; a carriage comprising a pair of cupping arms to secure an open beverage cartridge beneath the dispensing element, the carriage further comprising a rotating lid holder on which to situate a lid of the open beverage cartridge; a lever linked to the dispensing element so as to rotate the dispensing element, in response to the lever being actuated, and release the certain amount of the substance stored in the dispensing element into the open beverage cartridge; and a lid closing pin arranged to contact the rotating lid holder of the carriage in order to rotate the lid holder and seal the lid of the beverage cartridge as the carriage moves in a first direction along a first axis.
 2. The beverage cartridge assembler of claim 1, further comprising a hopper for storage of an additional amount of the substance for brewing, the hopper comprising an opening with a channel to allow the certain amount of the substance to be received by the dispensing element.
 3. The beverage cartridge assembler of claim 2, wherein the hopper further comprises a coffee grinder.
 4. The beverage cartridge assembler of claim 1, further comprising a sliding linkage arm arranged to slide in the first direction along the first axis as the carriage also moves in the first direction along the first axis.
 5. The beverage cartridge assembler of claim 4, further comprising a beverage cartridge storage chamber to store a plurality of additional open beverage cartridges, the beverage cartridge storage chamber comprising a rotating sleeve.
 6. The beverage cartridge assembler of claim 5, wherein the sliding linkage arm is arranged to make mechanical contact with the rotating sleeve, while the sliding linkage arm moves in a second direction along the first axis, to discharge an additional open beverage cartridge into the cupping arms of the carriage.
 7. The beverage cartridge assembler of claim 5, wherein the open beverage cartridge comprises sidewalls with a plurality of vertical notches to permit the sidewalls to be flexible, in response to stacked in the beverage cartridge storage chamber.
 8. The beverage cartridge of claim 7, wherein the beverage cartridge has a diameter and an angle such that the sidewalls are at a distance of less than 0.005 inches of a brewing chamber wall, in response to the beverage cartridge being placed in a brewing chamber.
 9. A beverage cartridge comprising: sidewalls in a first position, the sidewalls having a plurality of vertical notches so as to permit the sidewalls to flex inward into a second position, in response to pressure being applied on the beverage cartridge, the sidewalls being able to return to the first position in response to the pressure on the beverage cartridge being released.
 10. The beverage cartridge of claim 9, wherein the beverage cartridge has a diameter and an angle such that the sidewalls are at a distance of less than 0.005 inches of a brewing chamber wall, in response to the beverage cartridge being placed in a brewing chamber.
 11. A beverage cartridge comprising: a sidewall that includes a first filter; a bottom portion that includes a second filter thicker than the first filter; and a plurality of slits on the bottom portion to support the second filter.
 12. The beverage cartridge of claim 11, wherein the first filter is approximately 0.005 inches thick.
 13. The beverage cartridge of claim 12, wherein the second filter is approximately 0.010 inches thick. 